Versatile panel with internal extruded profiles

ABSTRACT

This invention is mainly used to assemble diverse panels in a simple, efficient and secure manner. These panels can be used to make cabinets such as kitchen cabinets, garage or basement storage cupboards but also for use in commercial applications such as laboratories, offices, workshops and so on. Its main component is a rigid peripheral frame which serves as a base structure onto which are put flat surfacing materials such as glass, metal, wood or any of a variety of composite materials normally used for making cabinetry.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates generally to doors and cabinetry but more particularly to a system of assemblable panels for multipurpose usage as doors or cabinetry doors.

2. Background of the Invention

Extrusion frames have been known and used for years, especially in the making of window frames as several patents attest to. Extrusion profiles have also been used for creating various structures but many of these frames are meant to be permanent once they are assembled. Those that are meant to be dissassemblable usually require visible exposed screws or similar mechanical fastening means. These visible mechanical fastening means can mar an otherwise esthetically pleasing surface. There is therefore a need for an assembly process and method to make easily assemblable and disassemblable panels having invisible fastening means.

SUMMARY OF THE INVENTION

This invention is mainly used to assemble diverse panels in a simple, efficient and secure manner. These panels can be used to make cabinets such as kitchen cabinets, garage or basement storage cupboards but also for use in commercial applications such as laboratories, offices, workshops and so on. Its main component is a rigid peripheral frame which serves as a base structure onto which are put flat surfacing materials such as glass, metal, wood or any of a variety of composite materials normally used for making cabinetry.

The panel contains internal extruded profiles. Its applications are versatile (flush panel, glazed panel, door panel, single or double panel, etc.). It can be used indoors as well as outdoors, and once assembled, there are no visible screws or mechanical fasteners of any kind. The panel also allows for easy replacement of defective or broken parts and can be assembled as a kit.

The panel is easy to manufacture without no need for bending or folding tools and does not require any welding of parts at all. The frame structure is solid, durable and weather resistant. The panels can accept most of the standard accessories used in cabinetry such as hinges and handles.

Because there are no visible mechanical fasteners the finished surface can be made very smooth, moreover, it can be made entirely of aseptic materials such as stainless steel and/or aluminum si it can produce cabinet frames and doors that will not harbor germs, which is ideal for hospitals and laboratories.

The foregoing and other objects, features, and advantages of this invention will become more readily apparent from the following detailed description of a preferred embodiment with reference to the accompanying drawings, wherein the preferred embodiment of the invention is shown and described, by way of examples. As will be realized, the invention is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the invention. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as restrictive.

BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENT

FIGS. 1 abcd cross sectional views of the base elements of the profiles.

FIGS. 2 ab cross sectional views of sample profiles

FIGS. 3 abc front elevation of a frame being assembled in its open configuration with partial profiles in top elevations.

FIGS. 3 de continuing with the frame being assembled in semi closed, and closed configuration respectively.

FIG. 4 Perspective view of frames prior to assembly with block spacer.

FIGS. 5 abc front face of a panel, top side of a panel, and side cross section of a panel, respectively.

FIGS. 6 ab Front elevation of a panel with hinges and and front elevation of a panel with a handle, respectively.

FIGS. 7 abcd Show various front elevations of combinations of profiles to make a variety of panels.

FIGS. 8 ab front elevation of a glazed panel and top elevation of the profile, respectively.

FIGS. 9 abc side, front and back views of a panel, respectively.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIGS. 1 a-d show the 4 base elements from which all profiles are built. Element 1 a (100) has a flat surface (12) and a pair of hooks (14). Element 1 b (200) has an edge (16), channels (56), and a profile fin (18) Element 1 c (300) has a hookable groove (20), channels (56), and clips (46) Element 1 d (400) has a little hook (22) and a trim face (24)

Using these elements in combination produces profiles (500, 600) such as in FIGS. 2 ab where elements 1 b, 1 c, and 1 d (200, 300, 400) are cojoined to create profile 2 a (500). Using elements 1 a, 1 b, and 1 c (100, 200, 300) produces profile 2b (600). Element 1 c (300) has legs (46) which snap into receiving protrusions (48) which are part of element 1 b (200).

Profiles 2 a (500) and 2 b (600) show other components not part of the profiles per se such as a locking trim (26) which has both a decorative and a useful purpose which will be explained later.

Once a profile (500 or 600) is partially assembled, finishing surfaces known as fascia (28) are inserted, but more on that later. With these two profiles (500 and 600), a frame (30) can be assembled.

Looking at FIG. 3 a, the first step in assembling the frame (30) is in having corner threaded mechanical fasteners (32), that is one pair per each corner of the frame (30) in position AA as determined by the position of threaded mechanical fasteners (32) in relation to their slots (34). The vertical section of the frame (30′) has two vertical slots while the horizontal section of the frame (30″) has two horizontal slots and all of the slots are designed to afford a certain range of motion to each section of the frame (30′, 30″). At any rate, the orientation of the slots (34) is always so that their long side is running parallel to the length of that particular section of frame (30′ or 30″), whether these sections are from profiles 2 a or 2 b (500, 600). At the intersection of both frames (30′, 30″) Only elements 1 b (200) as per FIGS. 3 bc but beyond the intersection, element c (300) can be added. In position AA the frame (30) is expanded and can receive a first fascia (28) (shown in FIG. 5 a), the size of the fascia (28) is such that it is slightly larger than what the inner perimeter of the frame (30) will be once closed, that way, when moving from position AA to position BA as per FIG. 3 d, where the vertical section of the frame (30′) is closed in, the edges of the fascia are inserted into slits (42) as seen in FIG. 5 bc. The threaded mechanical fasteners (32) are still accessible and remain accessible even when moving to position BB as per FIG. 3 where both the horizontal and vertical sections of the frame (30′, 30″) are closed in. Once closed in, the mechanical fasteners can be tighten to secure the assembled frame. Of course, the order in which the frame is closed in whether the horizontal side of the frame or the vertical side is of no importance.

FIG. 4 shows a block spacer (70) which lies between frame (30′) and frame (30″), the thickness of the block spacer (70) depends upon the thickness of the edge (16).

An assembled panel (38) can be seen in FIG. 5 a where the frame (30) holds in the fascia (28). After the first fascia (28) is put in, a solid core (36) can be fitted inside the frame (30) to add strength to the panel (38). In the configuration shown in FIGS. 5 abc, the frame (30) is made up of element 1 b (200) for the top and bottom horizontal frame (30) and profile 2 b (600) is used for the left and right sides. Of course permutations are possible and element 1 b (200) could be placed vertically and profile 2 b (600) horizontally, it all depends on the orientation of the panel (38) as a whole and the terms horizontal and vertical are strictly to facilitate description in the context of FIGS. 5 abc. Also, FIG. 9 abc shows both the front and back of a panel with the difference when the front side FIG. 9 b has element 1 d (400) at the top and FIG. 9 c which shows the back of the panel without element 1 d (400). The apparent frame is the edge (16) of element 1 b (200). As can be best appreciated from FIG. 4 b, fascia (28) is inserted into slits (42) of element 1 b (200) while the solid core (36) is encased within elements 1 a (100) on at least two sides, possibly all four.

This is but one of many possible panel (38) configurations. Inserting a second fascia (28′) as in FIG. 2 a for the second face of the panel (38) is different than inserting the first fascia (28). As explained earlier, after inserting the first fascia (28) the frame (30) is closed in so that the second fascia (28′) can hardly be inserted in a way where its perimeter is inserted into the slits (42). In order to achieve insertion of the second fascia (28′), it is first bent convexedly and then relaxed so that the edges along its length can slide into slits (42) of element 1 b (200) and then it is slid along its length so that its first wide side can be fitted into yet another slit (42). At this point, 3 out of 4 sides are properly inserted into slits (42), now for the second wide side, the final side, the second fascia (28′) having been cut slightly shorter in length than the first fascia (28), has a gap left between it and the fourth slit (42), this gap is filled in by element 1 d (400) as per FIG. 2 a which is fitted so that its little hook (22) engages a complementary notch (44), part of element 1 c (300). Inserting element 1 d (400) thusly still leaves a little gap which is filled by the spacer trim (26) inserted between element 1 d (400) and the edge (16).

This method of installation, with minor variations, is applied to the various panel (38) configurations. Looking back at FIG. 5 a, one side shows a configuration as per FIG. 7 a while the other side, because it is framed using element 1 a (100) would look more like FIG. 7 b or FIG. 7 d.

For a panel with glass as per FIG. 8 a, profile 2 a (600) is used with a pane of glass (50) along with element 1 a (100) on either side acting as a framing device. A seal (52) can be readily accepted by element 1 c (300). Sealing gaskets (54) can also be inserted in available channels (56) made into element 1 b (200) and element 1 c (300)

Element 1 b (200) can have different thicknesses while keeping the rest of its profile identical, this allows for various thicknesses in panels.

Doors such as for cupboards can be made by adding hinges (58) and a handle (60) as in FIGS. 6 ab. 

1. A versatile panel with internal extruded profiles comprising: base elements; said base elements used in combination to create profiles; said profiles having slits and slots; said slots being used in combination with threaded mechanical fasteners.
 2. A versatile panel with internal extruded profiles as in claim 1 wherein: said base elements comprised of a first, second, third, and fourth element wherein a first element has a flat surface and a pair of hooks; a second element has an edge, channels, and a profile fin; a third element has a hookable groove, a complementary notch, channels and clips; a fourth element has a little hook, and a trim face.
 3. A versatile panel with internal extruded profiles comprising: base elements; said base elements used in combination to create profiles; said profiles having slits and slots; said slots being used in combination with threaded mechanical fasteners. said base elements comprised of a first, second, third, and fourth element wherein a first element has a flat surface and a pair of hooks; a second element has an edge, channels, and a profile fin; a third element has a hookable groove, channels and clips; a fourth element has a little hook, and a trim face.
 4. A versatile panel with internal extruded profiles as in claim 3 having the following method of assembly: said profiles combined to create a panel by having four profiles intersecting in order to form a frame having four sides; said intersection creating a corner wherein two intersecting profiles are being partially assembled by being loosely connected by way of said threaded mechanical fasteners moving within the range allowed by said slots and said spacing block used for setting a relative distance between said profiles; inserting a first fascia and then moving said profiles so as to completely encase said fascia within said slits; tightening said threaded mechanical fasteners so as to secure said frame; inserting a second fascia by bending said second fascia convexedly and then relaxing said second fascia so that the edges along its length can slide into said slits of said second element and; said second fascia being slid along its length so that its first wide side can be fitted into yet another slit; a second wide side having a gap filled in by said fourth element engaging said third element by way of said fourth element's said little hook engaging said complementary notch of said third element.
 5. A versatile panel with internal extruded profiles as in claim 4 wherein the method further includes inserting a spacer trim between said fourth element and said edge.
 6. A versatile panel with internal extruded profiles as in claim 4 wherein; a profile using a pane of glass instead of fascia has said first elements on either sides acting as a framing device, over a profile using a combination of said second and third elements; a seal inserted into said third element to interface between said pane of glass and said third element.
 7. A versatile panel with internal extruded profiles as in claim 6 wherein; having sealing gaskets being inserted into said channels.
 8. A versatile panel with internal extruded profiles as in claim 3 further comprised of a first and second fascia.
 9. A versatile panel with internal extruded profiles as in claim 3 further comprised of a first fascia and a solid core.
 10. A versatile panel with internal extruded profiles as in claim 3 further comprised of a first and second fascia, and a solid core.
 11. A versatile panel with internal extruded profiles as in claim 3 further comprised of a first fascia, a solid core and hinges.
 12. A versatile panel with internal extruded profiles as in claim 3 further comprised of a first and second fascia, a solid core and hinges.
 13. A versatile panel with internal extruded profiles as in claim 3 further comprised of a first and second fascia, and hinges.
 14. A versatile panel with internal extruded profiles as in claim 3 further comprised of a first fascia, a solid core, hinges, and a handle.
 15. A versatile panel with internal extruded profiles as in claim 3 further comprised of a first and second fascia, a solid core, hinges, and a handle.
 16. A versatile panel with internal extruded profiles as in claim 3 further comprised of a first and second fascia, hinges, and a handle. 